Carton erecting and packaging machine

ABSTRACT

AN AUTOMATIC CARTON ERECTING AND PACKAGING MACHINE IS DESCRIBED. TUBULAR BUMPERS ARE AUTOMATICALLY FORMED ON A CARBON BLANK BY FOLDING THE BLANK&#39;&#39;S SIDE FLAPS OVER A FORMING BAR BY A SERIES OF ROLL-OVER CAMS. THE NEWLY FORMED BUMPERS ARE THEN SPREAD APART FOR THE INSERTION OF THE ARTICLE TO BE PACKAGED INTO THE PARTIALLY ERECTED CARTON. WHEN OPERATING WITH A DOUBLE (TWO PART) BLANK CARTON, THE FILLED CARTON AND ITS COVER ARE SIMULTANEOUSLY CONVEYED INTO ENGAGEMENT FOR THE FINAL GLUING AND CLOSING   OPERATION. WHEN OPERATING WITH A SINGLE BLANK CARTON, A CURVED PLOUGH CLOSES THE CARTON COVER AS IT IS CONVEYED TO THE FINAL GLUING AND CLOSING OPERATION. IN AN ALTERNATE EMBODIMENT, A CONTOURED FLIGHT WHICH CONVEYS THE CARTON BLANK THROUGH THE BUMPER FORMING OPERATION ALSO ENGAGES THE ARTICLE TO BE PACKAGED AND INSERTS IT INTO PROPER POSITION IN THE CARTON BLANK.

Dec. 14, 197] Q DORE-MANN CARTON ERECTING AND PACKAGING MACHINE 7 Sheets-Sheet 1 Filed April 7. 1970 INVENTOR. OSCAR DORFMANN ATTORNEYS Dec. 14, 1971 Filed April 7. 1970 FIG. 1b

0. DORFMANN CARTON ERECTING AND PACKAGING MACHINE 7 Sheets-Sheet z INVENTOR. OSCAR DORFMANN ATTORNEYS Dec. 14, 1971 o. DORFMANN 3,626,660

CARTON ERECTING AND PACKAGING MACHINE Filed April '7, 1970 '7 Sheets-Sheet 4.

FIG. 10 I .MH 1 |2| l .llllh Hill AHHH 76 I IIIHIII 76 liiijjIfl O O o eo-- \p INVENTOR. OSCAR DORFMANN YB W EMJ ATTORNEYS Dec. 14, 1971 Q om- 3,626,650

CARTON ERECTING AND PACKAGING MACHINE Filed April 7, 1970 7 Sh68tS-Sh6Bt 5 FIG. 11

INVENTOR. OSCAR DORFMANN ATTORNEYS Dec. 14, 197'] Q om- 3,626,660

CARTON ERECTING AND PACKAGING MACHINE Filed April 7, 1970 '7 Sheets-Sheet 6 N INVENTOR.

OSCAR DORFMANN ATTORNEYS Dec. 14, 1971 o. DORFMANN 3,626,660

CARTON ERECTING AND PACKAGING MACHINE Filed April 7, 1970 7 Sheets-Sheet 7 FIG. 16 W w w. m

INVENTOR. OSCAR DORFMA N N ATTOR NEYS United States Patent 3,626,660 CARTON ERECTING AND PACKAGING MACHINE Oskar Dorfmann, North Bergen, N.J., assignor to Grand- City Container Corporation, North Bergen, NJ. Filed Apr. 7, 1970, Ser. No. 26,227 Int. Cl. B65b 11/18, 25/14, 61/00 US. Cl. 53183 24 Claims ABSTRACT OF THE DISCLOSURE An automatic carton erecting and packaging machine is described. Tubular bumpers are automatically formed on a carton blank by folding the blanks side flaps over a forming bar by a series of roll-over cams. The newly formed bumpers are then spread apart for the insertion of the article to be packaged into the partially erected carton. When operating with a double (two part) blank carton, the filled carton and its cover are simultaneously conveyed into engagement for the final gluing and closing operation. When operating with a single blank carton, a curved plough closes the carton cover as it is conveyed to the final gluing and closing operation.

In an alternate embodiment, a contoured flight which conveys the carton blank through the bumper forming operation also engages the article to be packaged and inserts it into proper position in the carton blank.

This invention relates to a machine for automatically erecting, filling and closing cartons which have tubular side walls.

In packaging books and records for shipment, it has been found advantageous to utilize cartons having tubular side walls. The tubular side walls serve as bumpers which hold the article contained in the carton securely in place and provide protection for the corners of the article. In the single blank version of cartons of this type, the top or cover is integral with the rest of the carton. In the double blank version, the top is a separate piece. These cartons are often shipped to users with the bumpers erected and glued in place so that it is only necessary for the user to fill the cartons and close and glue the cover. However, because of the substantial freight costs involved in shipping the partially erected cartons, many users, especially the larger ones, prefer to have the carton blanks shipped to them unerected in a fiat position so that they can erect, fill and close the cartons themselves. On the other hand, many of the smaller users still prefer to have the cartons shipped to them in a partially erected condition so that all they must do is fill and close the cartons.

In order to meet the requirements of the larger users, automatic packaging machines have been developed which erect, fill and close the cartons. One problem with these conventional packaging machines is that a funnel and plough arrangement is used to erect the tubular bumpers. Unavoidably, a great amount of friction is produced during this operation and it often results in deforming the front edges of the carton bumper.

Furthermore, difficulty is encountered in many of the conventional packaging machines during the insertion of the article to be packaged into the partially erected carton because of the close fit between the bumpers and the article. This operation is often done manually because of these difficulties, thereby detracting from the automated nature of the system and causing further expense.

Another problem with these conventional automatic packaging machines is that they cannot be modified for the small user who only needs the machine for filling and closing the partially erected cartons. And, a further problem is that the machines are often only adapted for use Patented Dec. 14, 1971 with a single blank carton or a double blank carton, but not both.

Another problem with the conventional packaging machine is that it is usually adapted to operate only on carton blanks of a uniform size. However, many users are involved in packaging books, records and other articles and therefore require a machine which is capable of performing the erecting, filling and closing operations on carton blanks of various sizes.

It is accordingly an object of this invention to provide an automatic carton erecting and packaging machine for erecting, filling and closing single blank and double blank cartons with tubular side bumpers.

It is a further object of this invention to provide an automatic carton erecting and packaging machine which does not deform the front edges of a carton during the erecting of the cartons side bumpers.

It is a further object of this invention to provide an automatic carton erecting and packaging machine which automatically spreads apart the carton bumpers for easy insertion of the article to be packaged into the carton.

It is a further object of this invention to provide an automatic carton erecting and packaging machine which permits the filled carton to be transported to the closing operation without damaging the cartons bumpers.

It is a further object of this invention to provide an automatic carton erecting and packaging machine for a double blank carton whereby the movement of the filled lower half of the carton toward the closing operation is synchronous with the movement of the top half of the carton to the closing operation.

It is a further object of this invention to provide an automatic carton erecting and packaging machine which may be modified for use with partially erected or preformed cartons.

It is a further object of this invention to provide an automatic carton erecting and packaging machine for single and double blank cartons which is easily adaptable to carton blanks of different sizes.

This invention provides an automatic carton erecting and packaging machine for both single blank and double blank cartons which are fed into the machine unerected and also for single blank and double blank cartons which are fed into the machine with preformed bumpers. The invention is best understood by dividing its description into three sections corresponding to the machines functional gFBJEtlOHS, i.e., erecting, filling and closing the carton The first section of the machine is the erecting section in which tubular bumpers are formed on an initially flat carton blank. A longitudinally extending, continuously moving dual chain drive is mounted on appropriate supporting structure. Several flights are collapsibly mounted on the dual chain drive in order to engage the rear of a fiat carton blank and push it forwardly along the machines erecting section. The side flaps of the initially flat carton blank first engage a curved plough which raises the side flaps to an angle of approximately sixty degrees. Each carton then progresses to the bumper forming operation where a series of roll-over cams bend the cartons side flaps over a forming bar as the carton moves forwardly. The roll-over cams permit the bumper forming operation to proceed at a relatively high speed in comparison to the conventional erecting process where funnels are used. This is because the cams have only line contact with the side flaps of the carton thereby reducing the amount of friction involved in the operation. The newly formed tubular bumpers then engage channel-like guideways which insure that the bumpers retain their shape and which spread the bumpers at an angle away from the carton for easy insertion of the article to be packaged into the carton as the carton moves forwardly.

The filling section of the machine, in which the article to be packaged is inserted into the carton, is perpendicular to the machines erecting section. Two dual chain drives with synchronized, intermittent stop and go motion extend the length of the machines filling section. A collapsible L-shaped flight is mounted on each of the dual chain drives so as to each engage a tubular bumper of the carton as it enters the machines filling and closing section. In the preferred embodiment, as the article to be packaged is approaching the machines filling section from one side, the carton is approaching simultaneously from the other side. The insertion of the article into the carton occurs when the two dual chain drives are stopped. After insertion of the article into the carton, the carton moves transversely toward the machines closing section.

In an alternate embodiment of the invention, a hopper full of articles to be packaged is positioned over the machines erecting section and a book positioning flight is substituted for the filling sections ordinary flight. The positioning flight is contoured so that its lower portion engages the rearward end flap of the carton and its upper section engages the lowermost article in the hopper and pushes it onto the carton blank as the blank progresses forwardly along the machines filling section. The positioning flight is contoured so that when the article is pushed out from the hopper it is correctly positioned in the carton blank. In this embodiment the bumper spreading operation is performed by the sides of the hopper.

In the closing section of the machine, glue is applied to the carton blank and the cover, and the cover is placed on the filled carton and secured in position. The packaged article is then transmitted to a conveyor for delivery to the customer. The machines closing section is located at the end of the two dual chain drives in the machines filling section and rises vertically from the machines filling section to the delivery conveyor. When a double blank carton is used for packaging the article, a cover conveying mechanism, which is located perpendicular to the machines filling section and aligned with the machines closing section, supplies a cover for the filled carton. As the cover and the carton approach the closing section simultaneously they both have glue applied to their surfaces. When the cover and the carton are exactly positioned, the two dual chain drives and the cover conveying mechanism (which are both connected by a right angle drive) stop and a piston positioned beneath the carton pushes it upwardly into engagement with its cover and into a carton stacking cage in which the glued sections of the carton and cover have sufficient time to dry. As each succeedlng carton and cover is pushed into the stacking cage, the preceding carton and cover is pushed upwardly In the open-top cage until it reaches a conveyor or other appropriate mechanism which transmits the packaged art1cle for delivery to the customer.

When a single blank carton is used to package the article, a curved plough in the machines filling section closes the cover of the carton before it moves into position in the closing section of the machine. The cover conveying mechanism, of course, is not needed in this operation. With this exception, the closing of the single blank carton proceeds the same as with a double blank carton.

Another feature of this invention is that the filling section of the machine is vertically adjustable so that cartons of various thicknesses can be operated on without the necessity of making several overhead adjustments.

Another feature of this invention is that the machines erecting section is horizontally adjustable and the distance between the L-shaped flights in the machines filling section is adjustable to accommodate cartons of varying widths.

A further feature of this invention is that the machine can operate on cartons with preformed bumpers of the single blank or double blank variety. This is simply accomplished by feeding the erected cartons into the machines erecting section and deactivating the roll-over cam drive. The cartons proceed to then move to the bumper spreading operation and continue through the machine in the same manner as the unerected cartons described above.

These and other objects and features of this invention will be more readily understood and appreciated by reference to the following descriptions and drawings, in which:

FIG. 1a is a perspective view of the front portion of the erecting section of the machine of this invention;

FIG. lb is a perspective view of the rear portion of the machines erecting section illustrated in FIG. la and of the filling and closing sections of the machine;

FIG. 2 is an enlarged, partial cross-sectional view of the erecting section of the machine illustrated in FIG. 1a, taken along the line 2-2;

FIG. 3 is an enlarged, partial cross-sectional view of the erecting section of the machine illustrated in FIG. 1a, taken along the line 3-3;

FIG. 4 is an enlarged, the erecting section of the taken along the line 4-4;

FIG. 5 is an enlarged, the erecting section of the taken along the line 5-5;

FIG. 6 is an enlarged, partial cross-sectional view of the erecting section of the machine illustrated in FIG. 1a, taken along the line 6-6;

FIG. 7 is an enlarged, partial cross-sectional view of the erecting section of the machine illustrated in FIG. 1a, taken along the line 77 FIG. 8 is an enlarged, partial cross-sectional view of the erecting section of the machine illustrated in FIG. 1b, taken along the line 88;

FIG. 9 is an enlarged, partial cross-sectional view of the erecting section of the machine illustrated in FIG. lb, taken along the line 9-9;

FIG. 10 is an enlarged side elevational view of a portion of the filling section of the machine of this invention taken along the line 1010 in FIG. lb;

FIG. 11 is an enlarged cross-sectional view of the filling and closing sections of the machine of this invention taken along the line 11-11 in FIG. 1b;

FIG. 12 is an enlarged, side elevational view of the closing section of the machine of this invention also partially illustrated in FIG. 1b;

FIG. 13 is a perspective view of the rear portion of a first alternate embodiment of the filling and closing sections of the machine of this invention adapted for a single blank carton;

FIG. 14 is a side elevational view of a portion of the erecting section of the machine;

FIG. 15 is a perspective view of a second alternate embodiment of this invention illustrating an article inserting mechanism; and

FIG. 16 is an enlarged cross-sectional view of the article inserting mechanism illustrated in FIG. 15, taken along the lines 1616.

In the following description, the automatic erecting and packaging machine of this invention is described in three parts, corresponding to the function that the particular section of the machine performs, namely, erecting, filling or closing the carton. Furthermore, the description of the preferred embodiment of the machine relates to its operation on an unerected, double-blank carton. In a first alternate embodiment of the machine, its operation on an unerected, single-blank carton is described. In a second alternate embodiment of the machine, a mechanism for inserting the article to be packaged into the carton blank is described. Since the mechanisms on each side of the various sections of the machine are the same and function in a similar manner, only the mechanisms on one side of the machine are described below except partial cross-sectional view of machine illustrated in FIG. 1a,

partial cross-sectional view of machine illustrated in FIG. la,

where the same mechanisms on opposite sides of the machine function differently.

(I) PREFERRED EMBODIMENT (a) Erecting section Referring to FIG. 1a, the front portion of the erecting section of the machine is illustrated. The remainder of the machines erecting section is illustrated in FIG. lb.

The lower blank 12 of a double blank carton is composed of side flaps 30 and forward and rearward edges 94. Score lines 30A, 30B, 30C and 30D are stamped into each of the carton blanks side flaps 30 to permit the side flaps to be more easily bent into tubular bumpers. When the carton blank is thick, the score lines 30A, 30B, 30C and 30D may be alternately cut to permit further ease in bending. The carton blank 12 is fed onto the machine in a substantially flat position by a conventional feeder.

The bottom surface of the carton blank 12 engages a split table wihch extends longitudinally the length of the machines erecting section. Two power chains 14 are positioned between split table 10. The power chains 14 are each driven by a wheel sprocket 16 which is attached to power axle 18. A source of power (not shown) is provided at one end of the power axle 18. A slidable gear wheel is also attached to power axle 18 on each side of the machine so as to engage a stationary gear wheel 22.

Depending vertically from the horizontal table 10 is vertical plate through which the power axle 18 1s slidably mounted at the beginning (referring to FIG. 1a, the left side) of the machines erecting section. The split table 10 is horizontally movable toward and away from the sprockets 16 in order to adapt the erecting section of the machine to a carton having a greater or lesser width than the carton illustrated in FIG. 1a. Accordingly, when table 10 is moved horizontally outwardly, the slidable gear wheel 20 must be adjusted a like degree to engage the stationary gear wheel 22.

As previously mentioned, when the carton blank 12 is initially placed onto the machine, it is in a substantially fiat position (not shown). A flight 24 which is collapsibly attached to the power chains 14 engages the rear of the carton blank 12 and pushes it forwardly along the length of the erecting section of the machine. There are several flights 24 spaced along the length of the machines erecting section each of which pushes a carton blank forwardly through the various operations to be performed in the erecting section. Since the movement of the power chains 14 is continuous, each of the cartons 12 is pushed uninterruptedly along the length of the machines erecting section.

A forming bar 26 which extends along a substantial part of the erecting section of the machine is supported on the horizontal table 10 by a U-shaped bracket 28. As explained in detail below, the purpose of the forming bar 26 is to provide :a member about which the side flaps 30 of the carton blank 12 may be bent in order to form the desired tubular bumpers. To accomplish this result, it is necessary that the forming bar 26 coact with the roll-over cams 32, 34 and 36 which are mounted on the vertically depending plate 25. The forming bar 26 is substantially the shape of a parallelogram and supported at an angle of approximately sixty degrees with the horizontal, as ilillustrated in FIGS. 2-7.

Referring now to FIG. 2, as the carton blank 12 progresses forwardly from its initial position on the machine, the blanks side flaps 30 each engage a curved plough 38 which is mounted on each side of the split table 10. The curved plough 38 forces the blanks side flap 30 to bend at score line 30A at an angle of approximately 60 with the horizonal as the carton blank progresses forwardly. While the curved plough 38 operates on the outer surface of the side flap 30, the forming bar 26 engages the inner surface of the side flap 30 and prevents it from folding over.

Referring back to FIG. la, the roll-over cams 32, 34 and 36 are each supported on the plate 25 depending vertically from the split table 10. The gear wheel 22 transmits rotational movement from the power axle 18 to the driven axle 40 which is rotatably mounted on vertical plate 25. Cams 42, 44 and 46 are each attached to the driven axle 40 and each respectively drives roll-over cams 32, 34 and 36 by respectively engaging rollers 48, 50 and 52 which are rotatably mounted at one end of lever arms 54, 56 and 58 respectively. Lever arms 54, 56 and 58 are respectively pivotally attached to roll-over earns 32, 34 and 36 and are each slidably mounted in a sleeve attached to the plate 25. The rotational motion transmitted to driven axle 40 by slidable wheel gear 20 causes earns 42, 44 and 46 to rotate thereby imparting rotational motion to roll-over earns 32, 34 and 36 respectively.

As the carton blank 12 progresses forwardly, the rollover cams coact with the forming bar 26 to form a tubular bumper from each of the side flaps 30. The curved plough 38, though shown partially broken away for illustration purposes in FIG. la, continues along the length of the machines erecting section to a point just short of rollover cam 32, so that as cam 32 is turning the leading end of the side flap 30, the curved plough 38 is maintaining the rear end of the side flap 30 at approximately a 60 angle.

A second carton blank 12 is illustrated in FIG. 1a after having progressed from its initial position in the machines erecting section to a position where each of the side flaps 30 is simultaneously engaged by the roll-over cams 32 and 34. A glue gun 60 is located between roll-over cams 32 and 34 on each side of the machine and supported from above (not shown) the horizontal table 10 so as to be in wiping contact with the carton blank 12 as it progresses forwardly along the machines erecting section. The glue is stored in a vat supported above the machine with hoses leading to each of the glue guns 60. The glue gun 60 applies a thin film of a conventional hot melt-slow working glue in two strips onto the top surface of the carton blank 12. Although the purpose of this glue application is to secure the tubular bumpers in place once they have been formed, this operation can be omitted when the fit between the tubular bumpers and the :article to be packaged is sufficiently tight that the sides of the article retain the formed bumpers in place.

Referring now to FIG. 3, the carton blanks side flap 30 is shown being bent over forming bar 26- at score lines 30B and 30C by roll-over cam 32 while being supported by plough 38. Glue gun 60 applies glue to the carton blank 12. Only the tip of roll-over cam 32 contacts the carton blanks side flap 30 in forming bends in the side flap at score lines 303 and 300. As a result, there is only line contact between roll-over cam 32 and the side flap 30. As the cam rotates through a predetermined number of degrees and the carton blank progresses forwardly, the line contact between the cam and the side flap generates an imaginary spiral on the side flap.

Since there is only line contact between the roll-over cam and the side flap, there is only a small friction between them. And since roll-over cams 34 and 36 have the same line contact with side flap 30 as cam 32, the amount of friction involved in erecting the tubular bumpers of the carton blank is relatively small in relation to the amount of friction produced by using funnels and the like in the bumper-forming operation. The reduced friction permits the operation to proceed at a relatively high speed.

Referring to FIGS. 3-7 and 14, a triangular member 27 is attached to the inside surface of forming bar 26 on a diagonal as illustrated in FIG. 14. The triangular member increases in cross-sectional area progressing from rollover cam 32 to the middle of roll-over cam 34 and decreases in cross-sectional area an equivalent amount progressing from the middle of roll-over cam 34 to the end of roll-over cam 36. The triangular member cooperates with the forming bar 26 to form the tubular bumpers by engaging the side flap 30 at various points as it is progressively bent over the forming bar by roll-over cams 32, 34 and 36.

When the rotation of the roll-over cam 32 is completed, the carton blanks side flap 30 is in the position illustrated in FIG. 4. In this position, the leading edge of side flap 30 is being bent over forming bar 26 and triangular member 27 by roll-over cam 34 while being supported by plough 38. Two strips of glue 61 have been applied to the top surface of the carton blank 12 by the glue gun 60. The bend in side wall 30 at score line 30B has been completed and the bend at score line 30C, which was initiated by roll-over cam 32, is given further definition by roll-over cam 34. Also, a bend at score line 30D in side flap 30 is formed by roll-over cam 34. Similar to roll-over cam 32, there is only line contact between roll-over cam 34 and the side wall 30.

Referring now to FIG. 5, the roll-over cam 36 engages the carton blanks side flap 30 and further defines the bends in the side wall at score lines 30C and 30D by bending the side flap over the forming bar 26 and the triangular member 27, with only line contact between the roll-over cam 36 and the side wall.

Referring to FIG. 6, the carton blank 12 is shown having progressed along the machines erecting section to the end of roll-over cam 36. In this position, the rotation of the roll-over cam 36 has been completed and a tubular bumper 30 has been formed from side flap 30. After the completion of the rotation of roll-over cam 36, right angle bends have been formed in the side .flap at score lines 30B, 30C and 30D.

Referring now to FIGS. 1a and 6, a guideway 62 is attached to each side of split table forward from the roll-over cam 36 so that the leading edge of a carton blanks tubular bumper enters the guideway 62 before the rearward edge of the carton blanks tubular bumper leaves the roll-over cam 36 as the blank progresses forwardly on the machine. The guideway 62 retains the newly formed tubular bumper in place.

Referring now to FIGS. 1a and 7, the carton blanks tubular bumper 30' is shown at a position on the machine at which the forming bar 26 begins to taper to a Smaller cross section, as illustrated in dotted lines. As the leading edge of the tubular bumper 30 is entering the guideway 62, the rearward edge of the bumper is leaving the forming bar 26. Although the guideway 62 is initially offset at an angle of approximately 60 with the horizontal in order to assure a smooth transition for the bumper from forming bar 26 which is also angled at 60, the guideway gradually twists to an angle of approximately 90 (FIG. lb) with the horizontal further along the length of the machine so that the tubular bumper is forced to an upright position and the portion of the bumper after the bend at score line 30D is brought into contact with the glue strip 61.

Referring now to FIG. 1b, the rearward portion of the machines erecting section is illustrated along with the filling and closing sections of the machine which are described in more detail below. In the rearward portion of the erecting section of the machine, a guideway 64 with overhead rollers 66 suspended on a conventional weight bar (not shown) is positioned on each side of split table 10 directly following the guideway 62. As previously mentioned, after the carton blanks tubular bumper 30' is formed by the roll-over cams, the bumper enters guideway 62 at an angle of approximately 60 and is twisted by it to an angle of approximately 90 so that when the bumper enters guideway 64, the slight pressure applied by the overhead rollers 66 is sufficient to glue the bumper in place. As illustrated in FIGS. 1b and 8, rollers 66 bear down against the top portion of the bumper 30" thereby forcing the lower portion of the bumper into engagement with the glue strips 61. The guide rails 64 prevent the side walls of the tubular bumper from buckling as the carton blank progresses forwardly along the machine's erecting section.

Referring again to FIG. 1b, as the carton blank progresses further along the machines erecting section to the position illustrated by line 9-9, the guide rails 64 angle outwardly approximately 10, as illustrated in FIG. 9, so that the tubular bumper 30 is bent outwardly. In this position the carton blank is ready to leave the machines erecting section and enter into the filling section of the machine. The tubular bumpers are bent outwardly so that they do not interfere with the insertion of the article 66 to be packaged into the carton, as described in more detail below. The bumper spreading operation is necessary because of the tight fit between the article 66 and the inner sides of the bumper after the article is packaged.

Referring again to FIG. lb, each set of angle cams 68 which are pivotally mounted on the power chains 14 pre vent the flight 24 corresponding to that particular set of angle cams from collapsing backwardly. The lower portion of each of the angle cams 68 engages a rail (not shown) which extends substantially the length of the erecting section of the machine. The forward and rear edges of the rail are tapered downwardly so that the angle cam 68 runs off the rail as the carton blank 12 approaches the filling section of the machine thereby allowing the flight 24 to collapse backwardly so as not to crush the carton blank 12 against the Stop plate 70 in the machines filling section. The flight 24 then proceeds around the underside of the power chains 14 and assumes an upright position as it reaches the upper side of the power chain so that it is in a position to push the rear edge of another carton blank forwardly.

(b) Filling section Although the movement of the power chains 14 in the erecting section of the machine is continuous, the movement of the two adjacent sets of power chains and 76 is the filling section is intermittent. A piling up of carton blanks in the filling section is prevented by positioning the flights 24 in the erecting section a suflicient distance apart so that the filling section power chains 75 and 76 progresses forwardly one unit before the erecting sections dual chain drive 14 presents another carton blank for filling.

The carton blank 12 is initially stamped (sized and pre-scored) so that the article 66 to be packaged fits snugly between the carton blanks tubular bumpers 30'. Simultaneous with the forward movement of the carton blank 12 toward the machines filling section is the movement of the article 66 down a conveyor 72 toward the carton blank 12. As the carton blank 12 leaves the machines erecting section, guide rails 64 maintain the rearward portions of the cartons bumpers at an angle of approximately with the horizontal (FIG. 9). The forward portions of the cartons bumpers are simultaneously being held apart by engagement with article 66 which is being pushed by pusher 74 into the carton blank. Thus, the article 66 and the guide rails 64 coact so that bumpers are continuously held spread apart as the carton blank leaves the machines erecting section and enters its filling section.

Referring to FIG. 1b, the conveyor 72 is positioned at an inclined angle. The pusher 74 has a projecting end 73 which pushes the article 66 down conveyor 72 and into the partially erected carton blank 12. The pusher 74 which moves forwardly in a slant on the conveyor 72 is driven by a motor which is synchronized with the movement of the carton blank 12 into the machines filling section. The height of the lower edge of the conveyor 72 is greater than the height of the stop plate 70 so that the plate does not interfere with the pushing of the article 66 into the carton blank.

Referring now to FIGS. lb and 10, the article 66 to be packaged is shown about to be inserted into the carton blank 12 which is progressing forwardly toward stop plate 70. The outer surfaces of the forward portions of the bumpers of the carton blank 12 are engaged by the flights 77 and 78 which are attached to power chains 75 and 76 respectively in the filling section. Angle earns 80, which are each attached to the filling section flights 77 and 78, each engage rails 82 and 83 respectively which are supported beneath the filling sections drive chains 75 and 76. Rails 82 and 83 angle upwardly for a short distance at the intersection of the erecting and filling sections of the machine and then proceed on a level along the length of the machine to beneath the closing section of the machine where the rails 82 and 83 angle downwardly (as illustrated in FIG.

As a result of the initial angling of rails 82 and 83 at the intersection of the filling and erecting sections of the machine, the flights 77 and 78 are initially bent outwardly to receive the carton blanks tubular bumpers 30'. As the filling sectionss drive chains 75 and 76 progress forwardly along the length of the filling section, each of the angle cams 80 respectively engages the level portions of rails 82 and 83, thereby forcing flights 77 and '78 to assume a substantially vertical position. Since the tubular bumpers of the carton are retained by the flights 77 and 78, the bumpers also are forced to a substantially vertical position as the drive chains progresses forwardly along the machines filling section.

Although the article inserting mechanism is located in the machines filling section in the preferred embodiment, it could be located completely in the machines erecting section (as described in the second alternate embodiment) or at another position along the machines filling section.

Since flights 77 and 78 are identical, only flight 78 is described in detail. Flight 78 is composed of a side wall 78' and a top wall 78" which is pivotally attached to the side wall so that it is free to rotate away from the top surface of the blanks tubular bumper. A spring 78" urges the flight top wall 78" to the closed position illustrated in FIG. 10. It is necessary for the top wall to be pivotally attached because when the packaged tubular wall carton is pushed upwardly in the closing section of the machine, as described in detail below, the top wall 78" must open upwardly, as illustrated in FIG. 12.

Flight 77 is attached to outer drive chains 75 and flight 78 is attached to inner drive chains 76. The outer drive chains 75 are adjustable by their sprockets so that flight 77 can be moved forwardly and rearwardly thereby adjusting the distance between flights 77 and 78 to conform to the width of the carton blank 12.

Although the movement of the drive chains 75 and 76 is intermittent, it is synchronized with the movement of the erecting sections d-ual chain drive by adjusting the speed ratio between the drive chains 75 and 76 and the drive chains 14. This is accomplished by connecting the filling section driver axle 84 to an appropriately timed power source. After the article 66 has been completely inserted into the carton blank 12, the drive chains 75 and 76 are activated and the filled carton progresses forwardly along the filling section of the machine towards its closing section.

Referring now to FIG. 11, posts 86 which are located at one end of the filling section of the machine and two similar posts (not shown) which are located at the other end of the machine provide support for the machines filling section. A bracket 88 is adjustably mounted on each of the supporting posts 86 so that the bracket may be raised or lowered. In FIG. 11 the bracket is shown in its lowered position. Horizontal table 90 on which the carton blank 12 travels as it progresses along the length of the erecting section of the machine is supported on the top surface of each bracket 88. Curved ploughs 92, illustrated in FIG. 1b, raise the forward and rearward edges 94 of the carton blank from a horizontal position to a vertical position. When the carton blank 12 is initially placed in the erecting section of the machine, the forward and rearward edges 94 of the carton blank 12 are in a horizontal position. As the carton progresses forwardly along the length of the machines erecting section, the

10 cartons rearward edge is pushed by flight 24 into the filling section of the machine. While the carton blank is in the machines erecting section it is necessary to maintain its leading edge in a horizontal position so that the article 66 may be inserted into the carton with no interference. The curved ploughs 92 raise the cartons forward and rearward edges 94 to a vertical position so that they will be in position for the final gluing and closing operation.

The drive chains 75 and 76 are rotatably supported on an axle 96, each end of which is journalled into one of the supporting posts 86.

A lead screw 98 is threaded into one of the supporting brackets 88. A gear wheel 100 is attached to the nonthreaded portion of the lead screw so as to engage a driver gear wheel 102 which is connected to a rotating power source (not shown). By a sprocket and chain belt arrangement, the rotary motion imparted to the lead screw 98 by the power source is also transferred to lead screw 104 which is threaded into the other supporting bracket 88.

In operation, when the power source is activated the driver gear wheel 102 imparts rotational movement to lead screws '98 and 104. Since the lead screws are each attached to crossbar 106, the rotational movement of the lead screw causes supporting brackets 88 to move upwardly or downwardly. The wing nuts 108 which secure the supporting brackets to posts 86 are, of course, loosened before vertical adjustment of the supporting brackets is begun. Once the vertical adjustment is completed, the brackets 88 and all the structure that the brackets support are in a raised position. Thus, the horizontal table and the curved ploughs 92 may all be raised or lowered by the vertical adjustment of the supporting brackets 88 while the chain drives 75 and 76 remain at the same horizontal level.

The vertical adjustability feature of the filling section of the machine enables the machine to operate on cartons having different thicknesses. For purposes of this discussion, a carton having a shallow depth is designated a normal size carton and a carton having a greater depth is designated a large size carton.

When an article is to be packaged in a normal size carton, the carton blank is initially placed in the erecting section of the machine. The carton blank then progresses along the erecting section during the formation of its tubular bumpers and progresses to the filling section of the machine where an article is inserted into the carton as described above. During this operation, the filling section of the machine is at its raised level (the opposite of which is shown in FIG. 11). When the filling section of the machine is at its raised level, the height of the table 90 is slightly greater than the non-adjustable height of the table 10 in the erecting section of the machine.

In order to permit smooth transmission of the normal size carton from the machines erecting section to its filling section, the filling section table 90 is angled slightly downwardly (not shown) where the erecting section intersects the filling section for a distance approximately equivalent to the width of the carton. A carton exiting from the machines erecting section encounters the slightly angled portion of table 90 and progresses forwardly to the horizontal portion of table 90 without encountering any diflficulty due to the differences in height between tables 10 and 90.

When an article is to be packaged in a large size carton, certain adjustments must be made in the erecting section of the machine to compensate for the increased length of the carton blanks side flap 30 which provides the carton with its greater depth. The roll-over cams 32, 34 and 36, the guideway 62, the guide rails 64 and the forming bar 26 must be replaced or adjusted to accommodate the larger size bumpers. After these adjustments have been made, the large size carton blank progresses along the erecting section of the machine during the 11 formation of its bumpers in the same manner as a normal size carton.

If the filling section of the machine is retained at the raised level used for normal size cartons, the large size carton would interfere with the closing ploughs 120 which face the filling section of the machine and which form part of the carton-stacking cage 122. Although the closing ploughs 120 which face the filling section of the machine are shown cut away in FIG. 11 in order to illustrate another feature of the invention, they extend the length of the other closing ploughs 121 which form the rest of the carton-stacking cage 122. In order to over come this interference problem, it is necessary to lower the operating surface of the machines filling section to the position which is illustrated in FIG. 11. In this position, the large size carton 123 fits beneath the cartonstacking cage 122 so that there need not be any overhead adjustments when a large size carton is used. Since the erecting section table is the same height as the filling section table 90 when it is adjusted for a large size carton, there is a smooth transmission of the large size carton between the machines erecting and filling sections.

As illustrated in FIG. 1b, the carton blank 12 progresses along the length of the filling section of the machine to beneath the carton-stacking cage 122. Glue guns 124 and 126 (FIG. 11) are positioned on each side of the machines filling section so that they are in wiping contact with the turned-up rearward and leading edges 94 of the carton blank 12. As the carton blank 12 progresses along the filling section of the machine past the glue guns, a strip of glue is deposited on the outer surface of the rearward and forward edges 94 of the carton.

One of the advantages of the vertical adjustability feature of the filling section of the machine is that the glue guns 124 and 126 need not be vertically adjusted for differences in the thicknesses of various size cartons. These differences are compensated for by adjusting table 92. As illustrated in FIG. 11, the glue gun 126 is positioned higher than the glue gun 124. This permits easier opening of the packaged carton by the user by providing an unglued portion of the carton cover flap which may be easily grasped and torn open.

After the gluing operation, the carton blank 12 continues forwardly along the machines filling section until the carton is positioned directly beneath the carton-stacking cage 122. The exact positioning of the carton is accomplished by timing the intermittent travel of the drive chains 75 and 76 so that when the carton blank 12 is positioned directly beneath the carton-stacking cage 122,

the drive chains stop.

As illustrated in FIG. lb, a stack of carton tops 13 is positioned in a hopper or other suitable dispenser directly in line with the carton-stacking cage 122. The movement of a carton top 13 to a position directly over the carton blank 12 is provided by drive chains 140 which are connected by a right angle drive or similar device to the drive chains 76' in the machines erecting section. Accordingly, the intermittent motion of the machines filling section is transferred to the drive chains 140.

Each of the carton tops 13 in FIG. lb is pulled out from the bottom of the hopper (not shown) holding the stack of carton tops by a conventional suction puller composed of a timed vacuum pump with suction cups. The actuation of the vacuum pump is timed to synchronize with the intermittent motion of the filling sections drive chains. The suction cups engage the bottom surface of a carton top 13, pull it down from the hopper and deposit it on a horizontal table from which it is pushed forwardly to the carton-stacking cage 122 by a flight attached to the drive chains 140. As the carton top 13 progresses forwardly along the drive chains 140, glue guns 142 positioned on either side of the drive chains deposit strips of glue on the bottom surface of the carton tops end flaps 15. The flight which pushes the carton 12 top into the carton-stacking cage 122 is the same as and operates similarly to flight 24 in the machines erecting section.

Referring again to FIG. 11, a stop plate 144 is attached to supporting plate 146. The stop plate ensures that the carton top 13 is positioned directly above the carton blank 12, The carton top 13 progresses along guide rails 148 as it enters the carton-stacking cage 122. The movement of carton blank 12 and carton top 13 into position beneath the carton-stacking cage is synchronized so that the top and blank reach the position beneath the cage at exactly the same time.

(c) Closing section The filled carton blank 12 is now ready for closing. Referring to FIG. 12, filled carton blank 12 is positioned directly beneath the carton-stacking cage 122. Carton top 13 is positioned directly above the filled carton blank 12. Cartons in various stages of closing in the cartonstacking cage are designated 19, 21, and 23. At this moment, the drive chains in the filling section of the machine stop and the piston pusher 150 is actuated. The movement of the piston pusher 150 is synchronized with the inserting of the article into the carton blank in the filling section of the machine. The pusher 150 engages the bottom surface of the carton blank 12 and pushes the filled carton upwardly so as to engage carton top 13. As the filled carton blank 12 rises, the carton tops end flaps 15 engage the curved closing ploughs and 121 (FIG. 10) which bend the end flaps into engagement with the sides of the cartons tubular bumpers,

The piston pusher pushes the closed carton upwardly until it passes the camming elements 154 which are pivotally mounted on the inside of the carton-stacking cage. Once the carton 12 has been pushed past the cams 154, the cams pivot downwardly so as to hold the carton in the position illustrated by carton 23. As a carton progresses further upwardly in the carton-stacking cage as a result of being pushed from beneath by the following carton to be closed, a greater pressure is applied to the sides of the carton to ensure that the end flaps of the carton are sealed to the side walls of the carton. This is produced by slightly angling the closing ploughs 120 and 121 so that the perimeter of the carton-stacking cage 122 tapers slightly from the bottom to the top. The packaged and glued cartons remain in the carton-stacking cage a suflicient time to permit the glue to dry and set.

The flights 77 and 78 are hinged at the top so that when the carton 12 is pushed upwardly, the hinges open providing no resistance to the cartons upward movement. When the movement of the drive chains begins again, the angle cams 80 run off their respective angled tracks 82 and 83, travel around the underside of the machines filling section and back to the position illus trated in FIG. 10. Referring again to FIG. 1b, a continually moving conveyor belt has a flight attached to it which pushes the cartons coming out of the cage down a chute 172 for delivery.

( ll) FIRST ALTERNATE EMBODIMENT Referring now to FIG. 13, an alternate embodiment of the automatic carton erecting and packaging machine of this invention is illustrated In the preferred embodiment, the operation of the machine is described on a double blank carton; in this embodiment, the operation of the machine on a single blank carton is described.

As previously mentioned, in a single blank carton the carton top is integral with the lower carton blank. Accordingly, there is no need in this operation for the separate conveying of carton tops into engagement with corresponding lower carton blanks. Furthermore, the only adjustment that must be made in the erecting section of the machine to accommodate the single blank carton is the longitudinal distance between the flights 24. The flights 24 should be spaced approximately twice as far apart as when a double blank carton is being operated on. The formation of tubular bumpers on the single blank carton and the inserting of an article to be packaged into the open carton also proceed the same as with a double blank carton, as described above. Accordingly, those features of the alternate embodiment of this invention designated by primed numerals respond to the same description as, and are the same as, those features in the preferred embodiment designated by corresponding numerals.

The major difference when operating on a single blank carton 113 is the addition of a top closing plough 200 onto the filling section of the machine, as illustrated in FIG. 13. Also, the closing plough 92' on each side of table 90' is lengthened so that the forward and rearward edges of carton blank 113 are raised from a horizontal position to a vertical position a short distance after the insertion of the article 66 into the carton blank. As the closing plough 92' engages the rearward edge of carton blank 113, the top closing plough 200 engages the top of the carton blank and progessively forces it over the carton blank as the blank proceeds forwardly along the machines filling section.

A glue gun 126' is supported on the table 90 above curved plough 92. As the carton blank 113 proceeds past the glue gun in wiping engagement, strips of glue are applied to the outer surface of the blanks forward edge. When the carton blank 113 is in position beneath the carbon-stacking cage 122', the drive chains 75' and 76' stop and the piston pusher forces the carton blank upwardly into engagement with the closing ploughs 121 which close edge 115 of the carton over the cartons glued surface.

As in the description of the preferred embodiment, each succeeding carton pushes the preceding carton higher in the carton-stacking cage 122' until the carton 113 reaches the top of the cage from which it is pushed to chute 172 by drive chain 170'.

(III) SECOND ALTERNATE EMBODIMENT Referring now to FIGS. 15 and 16, an alternate embodiment of the book inserting mechanism of this invention is described. In the preferred embodiment, the book inserting mechanism is positioned perpendicular to the path of the carton in the machines filling section and in line with the approaching carton blank in the machines erecting section. In this embodiment, the article inserting mechanism is positioned at the end of the erecting section of the machine. Since many of the features of the preferred embodiment are the same as those in this embodiment, those features of the embodiment designated in FIGS. 15 and 16 by primed numerals correspond to the same description as and are the same as, those features in the preferred embodiment designated by corresponding numerals.

Referring now to FIG. 15, a hopper 210 filled with articles 66 to be packaged is positioned at the end of the machines erecting section. Articles 66' are fed into the hopper 210 either manually or by a machine from the right, as indicated by the arrow in FIG. 15. The width of the hopper 210 at its base 208 corresponds to the inner width of the carton blank 12 being operated on by the machine. The hopper base 208 is tapered along its length so as to engage the inner surface of the bumper 30' which has been tilted outwardly by guideway 64'. In this way, the bumpers are held spread apart during the insertion of the article 66 as in the preferred embodiment.

Referring now to FIGS. 15 and 16, a book positioning flight 212 is attached to the two power chains 14. As in the preferred embodiment, the positioning flight 212 is collapsibly mounted on the power chains 14 by angle earns 68. Each angle cam 68 engages a rail 220 which is level along the length of the machines erecting section and which slopes downwardly as the carton blank approaches the perpendicularly extending drive chains 75 and 76'. As the angle cam 68' runs off the rail 220, the positioning flight 212 collapses downwardly, as indicated in dotted lines on the righthand side of FIG. 16. The downward slope in the rail 220 is arranged so that the flight 212 collapses downwardly when the filled carton blank 12' is completely positioned on power chains 75' and 7 6 in flights 77' and 78 respectively. A counterweight 218 which is attached to the flight 212 by a lever arm 216 causes the flight to collapse downwardly when angle cam 68 runs off rail 220.

The positioning flight 212 is composed of a lower section 214 and an upper section 213 which is mounted atop the lower section. The lever arm 216' is connected to the flights lower section 214. The flights lower section 214 cooperates with the lower part of the upper section 213 to provide a surface for pushing the carton blanks rearward edge 94 forwardly. The upper part of the flights upper section 213 extends forwardly from its lower part to engage the article 66 to be packaged and push it outwardly from hopper 210. The horizontal distance between the upper and lower engaging surfaces of the flights upper section 213 is approximately equivalent to the length of the carton blanks rearward edge 94'. Thus, the flight 212 does not begin pushing the article 66' out of the hopper 210 until the article is positioned directly over the carton blank 12'. In this way, the article is not pushed onto the forward or rearward end flaps 94' of the carton blank.

In operation, positioning flight 212 is progressing forwardly with drive chains 14 and pushing carton blank 12 by engaging its rearward edge 94. As the flight 212 approaches hopper 210, the upper part of the flights upper section 213 engages an article 66' and progressively pushes it outwardly from hopper 210 onto the carton blank 12'. As the article 66' is being pushed outwardly, the following article 66 to be packaged assumes the position of its predecessor in the hopper 210. When the carton blank 12' is positioned on drive chains 75 and 76', each angle cam 68' runs off the rail 220 and the flight 212 collapses downwardly. This prevents the filled carton blank 12' from being pushed off the drive chains 75' and 76.

When the book inserting mechanism of the second alternate embodiment of this machine is used, it is not necessary for the movement of the drive chains 75' and 76' to be intermittent, since the book inserting operation takes place in the machines erecting section. Accordingly, the movement of drive chains 75' and 76 is continuous and driver axle 84' is connected to driver axle 40 which extends the length of the machines erecting section. This speeds up the carton erecting, filling and closing process and permits the machine to handle sixty to seventy cartons per minute.

While embodiments of various aspects of the invention have been shown in the drawings, it is to be understood that this disclosure is for the purpose of illustration only and that various changes in shape, proportion and arrangement of parts, as well as the substitution of equivalent elements for those herein shown and described, may be made without departing from the spirit and scope of the invention as set forth in the appended claims.

I claim:

What is claimed is:

11. An automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular rectangular bumper from each of the carton blank side flaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, said bumper forming means comprising support means,

first folding means pivotally mounted on said support means and positioned so as to engage the carton blank side flap in line contact when the carton blank is transported past said first folding means, a bar mounted inwardly of said side flap from said first folding means on said support means and positioned so that the carton blank side flap is bent over said bar by said first folding means when the carton blank is transported past said first folding means, second folding means pivotally mounted on said support means rearward of said folding means and positioned so as to engage in line contact the carton blank side flap which has been partially formed into a tubular bumper by said first folding means, when the carton blank is transported past said second folding means, and third folding means pivotally mounted on said support means rearward of said second folding means and positioned to engage in line contact the carton blank side flap, which has been further formed into a tubular bumper by said second folding means, when the carton blank is transported past said third folding means.

2. The combination recited in claim 1 wherein said folding means comprises a generally 'C-shaped cam pivotally mounted to said support means.

3. An automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side flaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, said bumper forming means comprising support means, folding means pivotally mounted on said support means and positioned so as to engage the carton blank side flap in line contact When the carton blank is transported past said folding means, a bar mounted inwardly of said side flap from said folding means on said support means and positioned so that the carton blank side flap is bent over said bar by said folding means when the carton blank is transported past said folding means, said bar being generally in the shape of a parallelogram and being inclined at an angle of approximately 60 with the bottom of the carton blank when the blank is transported past said bar.

4. An automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side fiaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, said bumper forming means comprising support means, folding means pivotally mounted on said support means and positioned so as to engage the carton blank side flap in line contact when the carton blank is transported past said folding means, a bar mounted inwardly of said side flap from said folding means on said support means and positioned so that the carton blank side flap is bent over said bar by said folding means when the carton blank is transported past said folding means, and

means for actuating said folding means into engagement with the carton blank side flap to fold said 16 flap against said bar according to a pre-selected folding pattern. 5. The combination recited in claim 4 wherein said actuating means comprises a first shaft which is rotatably mounted on said support means, means attached to said folding means for converting the rotary motion of said first shaft to back and forth pivotal motion of said folding means.

6. The combination recited in claim 5 further comprising carton transporting means which comprises a second shaft that imparts rotary motion to said first shaft.

7. An automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side flaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, said bumper forming means comprising support means, folding means pivotally mounted on said support means and positioned so as to engage the carton blank side flap in line contact when the carton blank is transported past said folding means, a bar mounted inwardly of said side flap from said folding means on said support means and positioned so that the carton blank side flap is bent over said bar by said folding means when the carton blank is transported past said folding means, and a second bar being generally triangular in cross-section and being mounted on the inward face of said first bar so as to engage the carton blank side flap as it is bent over said first and second bars by said folding means.

8. The combination recited in claim 7 wherein said second bar tapers from its center so as to form diminishing cross-sectional areas proceeding from the center to either end.

9. An automatic carton erecting and packaging ma chine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side flaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, said bumper forming means comprising support means, first folding means pivotally mounted on said support means and positioned so as to engage the carton blank side flap in line contact when the carton blank is transported past said first folding means, a bar mounted inwardly of said side flap from said first folding means on said support means and positioned so that the carton blank side flap is bent over said bar by said first folding means when the carton blank is transported past said first folding means, and second folding means pivotally mounted on said support means rearward of said first folding means and positioned so as to engage in line contact the carton blank side flap, which has been partially formed into a tubular bump er by said first folding means, when the carton blank is transported past said second folding means, said second folding means pivotal point being positioned on said support means above said first folding means pivotal point relative to the bottom of the carton being folded in order that said second folding means may begin. pivoting downwardly at a point where 17 said first folding means finishes pivoting downwardly.

10. The combination recited in claim 9 further comprising a third folding means which is pivotally mounted on said support means rearward of said second folding means and positioned to engage in line contact the carton blank side flap, which has been further formed into a tubular bumper by said second folding means, when the carton blank is transported past said third folding means.

11. The combination recited in claim 10 wherein said third folding means pivotal point is positioned above said second folding means pivotal point on said support means in order that said third folding means may begin pivoting downwardly at a point where said second folding means finished pivoting downwardly.

12. The combination recited in claim 10 wherein said first bar extends along said Support means from said first folding means to said third folding means.

13. An automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side flaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, and

means for inserting the article to be packaged into the carton blank, said article inserting means comprising a first conveyor, a flight attached to said conveyor, said flight having an upper and lower portion, said flight upper portion extending outwardly from said flight lower portion wherein said flight lower portion is for engaging the rearward edge of a carton blank and said flight upper portion is for engaging the article to be packaged and inserting it into the carton blank inwardly from the forward and rearward edges of the carton blank, said article inserting means further comprising a hopper for stacking the articles to be packaged and adapted to discharge a single article through its base, said hopper being positioned directly above the path of travel of said conveyor, said hopper having a central opening in the path of travel of said flight which permits said flight upper portion to engage the article to be packaged without interference from said hopper.

14. An automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side flaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, and

means for inserting the article to be packaged into the carton blank, said article inserting means comprising a first conveyor, a flight attached to said conveyor, said flight having an upper and lower portion, said flight upper portion extending outwardly from said flight lower portion wherein said flight lower portion is for engaging the rearward edge of a carton blank and said flight upper portion is for engaging the article to be packaged and inserting it into the carton blank inwardly from the forward and rearward edges of the carton blank, said tubular bumper forming means being positioned along said first conveyor and further comprising a hopper for stacking the articles to be packaged and adapted to discharge a single article through its base, said hopper being positioned rearwardly of said tubular bumper forming means along said conveyor, said hopper base being tapered downwardly so that the outwardly facing sides of said hopper base engage and spread apart the carton blank tubular bumpers to facilitate the insertion of the article to be packaged into the carton blank.

15. The combination recited in claim 4 wherein said transporting means comprises a first conveyor, a flight which is mounted on said first conveyor for engaging the rearward edge of the carton blank and a first table positioned on each side of said first conveyor for supporting the carton blank.

16. The combination recited in claim 15 wherein said transporting means further comprises a second conveyor which is positioned perpendicular to said first conveyor, a second flight which is mounted on said second conveyor for engaging the rear tubular bumper which is formed from the carton blank side flap and a second table positioned on each side of said second conveyor for supporting the carton blank.

17. The combination recited in claim 16 wherein said transporting means further comprises a piston extending perpendicular to the plane formed by the intersection of said first and second conveyors for engaging the carton blank bottom side and pushing the carton upwardly.

18. A automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, comprising:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side flaps to provide protection of the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, and

means for spreading apart the carton blank tubular bumpers in order to facilitate the insertion of the article to be packaged into the carton blank, said bumper spreading means comprising support means, a second guideway attached to said support means, said second guideway being twisted from an initially erect position to a tilted position in order to engage the tubular bumper formed from the carton blank side flap and tilt it outwardly for the easy insertion of the article to be packaged, said bumper spreading means further comprising a second support means, an L-shaped flight attached to said second support means and positioned directly adjacent said second guideway in order to engage the tubular bumper formed from the carton blank side flap as the carton blank moves from said first to said second support means.

19. An automatic carton erecting and packaging machine for use with an unerected carton into which an article is to be packaged, the carton blank having a bottom, forward and rearward edges, side flaps and a top, compnsrng:

means for transporting the carton blank through the carton erecting and packaging machine and means for forming a tubular bumper from each of the carton blank side flaps to provide protection for the packaged article, said bumper forming means engaging said carton blank by line contact engagement with each carton blank side flap, and

means for closing the carton blank, comprising a piston which normally extends vertically so as to engage the bottom side of the carton blank and push the carton blank upwardly into engagement with a carton top which is positioned directly above the carton blank and a cage formed by vertically extending bars arranged to correspond to the approximate crosssectional area of the carton blank, said cage being 19 positioned directly over said piston so that the up ward thrust of said piston forces the carton blank into said cage.

20. The combination recited in claim 19 wherein said bars are flared outwardly at their bottom ends so as to force the edges of the carton blank top into engagement with the sides of the carton blank and wherein said cage tapers in cross-sectional area from the bottom in order to increase the pressure of the sides of the carton blank as it moves upwardly in said cage.

21. The combination recited in claim 19 further comprising means to adapt the automatic carton erecting and packaging machine to cartons of varying depths.

22. The combination recited in claim 21 wherein said carton depth adapting means comprise a conveyor for transporting the carton blank toward said carton blank closing means, a table coextensive with said conveyor upon which the carton blank is supported as it is transported toward said carton blank closing means, said table being vertically adjustable so that said carton blank closing means need not be adjusted for various carton blank depths.

23. Apparatus for forming tubular rectangular bumpers on a carton blank having side flaps and rearward and forward edges, comprising a conveyor for transporting the carton blank from a first to a second position; support means positioned on said conveyor,

a plurality of C-shaped cams spaced along the length of said conveyor and sequentially actuated into line contact engagement with the carton blank side flaps,

a first bar mounted inwardly of said side flap from said C-shaped cams on said support means and positioned so that the carton blank side flap is bent over said bar by said C-shaped cams, and

a second bar being generally triangular in cross-section and being mounted on the inward face of said first bar so as to engage the carton blank side flap as it is bent over said first and second bars by said C-shaped cams.

20 24. Apparatus for inserting and positioning an article to be packaged into a carton blank having rearward and forward edges comprising a conveyor for transporting the carton blank from a first to a second position;

a hopper for dispensing the article to be packaged positioned above said conveyor; and a flight attached to said conveyor having upper and lower portions; said flight lower portion for engaging the carton blank rearward edge and said flight upper portion extending outwardly from said flight lower portion for engaging the article in said hopper and inserting it into the carton blank inwardly from the forward and rearward edges of the carton blank, said flight upper portion extending outwardly from said flight lower portion a length equal to the length of the carton blank rearward edge, said hopper having a central opening in the path of travel of said flight which permits said flight upper portion to engage the article to be packaged without interference from said hopper.

References Cited UNITED STATES PATENTS 3,530,643 9/1970 Levi 53209 X 3,513,630 5/1970 Lattke et al. 63--209 3,380,227 4/1968 Youngman et al. 53234 X 3,396,508 8/1968 Dorfmann 53209 X 3,398,661 8/1968 Mathes et a1 93-52 FOREIGN PATENTS 462,279 3/1937 Great Britain 9352 THERON E. CONDON, Primary Examiner N. ABRAMS, Assistant Examiner US. Cl. X.R. 

